Cosmetic applicator with handle having integrally formed stiffener

ABSTRACT

AN APPLICATOR ELEMENT MOUNTED ON A HANDLE TO SERVE THE GENERAL PURPOSE OF A BRUSH COMPRISES A BULBOUS BODY OF A SOFT, RESILIENT, FOAMED PLASTIC WITH THE CELLS OPEN TO PROVIDE COMMUNICATION AMONG THE CELLS AND TO PROVIDE NUMEROUS MINUTE OUTWARDLY OPEN CAVITIES FORMED BY THE OUTER CELLS. A STIFFENER ELEMENT PROJECTING FROM THE HANDLE IS ENCLOSED BY THE FOAMED PLASTIC APPLICATOR ELEMENT AND IS SUBSTANTIALLY SMALLER IN CROSS SECTIONAL AREA THAN THE APPLICATOR ELEMENT.

March 9, 1971 B. D. ASTON 3,568,235

' COSMETIC APPLICATOR WITH HANDLE HAVING INTEGRALLY FORMED STIFFENEROriginal Filed Aug. 11, 1967 75 I 7@ HGJO $35 flea/v0 0. A570/V INVENTOR52% J3 F1612 {ww- W A from/6y United States Patent O US. Cl. 244 4Claims ABSTRACT OF THE DISCLOSURE An applicator element mounted on ahandle to serve the general purpose of a brush comprises a bulbous bodyof a soft, resilient, foamed plastic with the cells open to providecommunication among the cells and to provide numerous minute outwardlyopen cavities formed by the outer cells. A stiffener element projectingfrom the handle is enclosed by the foamed plastic applicator element andis substantially smaller in cross sectional area than the applicatorelement.

CROSS REFERENCE TO RELATED APPLICATIONS This application is a divisionof my copending application Ser. No. 816,183, filed Apr. 11, 1969, andwhich in turn is a continuation of my application Ser. No. 660,124,filed Aug. 11, 1967, now abandoned.

BACKGROUND OF THE INVENTION Brushes are commonly mounted on handles toserve as means for applying various materials to various surfaces. Thepresent invention is directed to the need for circumventing certaindisadvantages and limitations that are inherent in such brushes, andespecially in the use of brushes to apply cosmetics.

One disadvantage of a conventional brush for use with cosmetics such asrouge, mascara, and eye shadow is that it is difficult to control thearea of application with close precision. A slight increase in pressuremay spread the brush beyond the desired area of application and toooften errant bristles diverge from the main body of bristles to defeatclose control. The need is for an applicator element that has and willmaintain well defined boundaries.

A related need is a brush that may be used for sidewise strokes withclose control of the width and length of the strokes. If a conventionalflat brush is moved sidewise to apply a stroke of material, the bristlesnecessarily bend laterally and the location of the stroke varies withthe degree of fiexure of the bristles. Consequently, it is not possibleto move a flat brush sidewise with such control as to be sure ofcovering a precisely defined area.

Another disadvantage is that a conventional brush has too limitedcapacity for retention of a fluid cosmetic after the brush is dippedinto the fluid. A brush has only limited capillary capacity and most ofthe fluent material that is being applied is retained on the brush bysimple adherence to the smooth outer surfaces of the individual bristlesof the brush.

Another need in many instances is for a brush that will make exceedinglylight contact with a skin area Ideally, such a brush should be as lightand soft as a feather not only for the comfort of the user but also toavoid any excessive tendency for the brush to wipe off previouslyapplied material.

A still further need is for a brush having special utility for theapplication of finely divided dry materials such as dry rouge andpowder. Such an improved applicator should, of course, permit accuratecontrol of the area of application and such a brush should be capable ofretaining a desirable quantity of the dry material when the brush isdipped into the dry material. Here again, a brush for the application ofdry material should make only light contact with a skin area to avoiddragging away previously applied dry material.

Finally, it is desirable that a cosmetic application be of a relativelysimple construction suitable for mass production by automatic orsemi-automatic machinery.

SUMMARY OF THE INVENTION The invention is based on the discovery that alight. soft, resilient foamed plastic such as foamed urethane hasspecial utility for use as an applicator for cosmetics or the like ifthe foamed plastic is of open cell construction. With the numerousminute or microscopic cells of the foamed plastic in communication witheach other, the foamed plastic has exceptional capacity for capillaryaction and the relatively large total volume of the voids of such anapplicator of a given size provides an exceptional capacity for theretention of a quantity of liquid cosmetic after the applicator isdipped into the liquid cosmetic.

A special advantage of such an applicator is that the open cells on theouter surface of the applicator constitute numerous closely spacedcavities that are opened to the exterior of the applicator. If theapplicator is used for applying a liquid cosmetic, initial contact ofthe applicator with the skin releases the liquid in the surface of thecavities of the applicator and thereafter the surface cavities aresupplied with reserve liquid from the deeper cells of the applicator. Ifthe applicator is dipped into a dry cosmetic such as face powder or dryrouge, the minute surface cavities of the applicator retain particles ofthe dry material and readily release the particles upon initial contactof the applicator with the users skin.

A further important advantage of an applicator made of a soft open cellfoamed plastic is that the applicator has definite boundaries which aremaintained when the applicator is brought into light pressure contactwith the skin. Since the applicator tends to maintain its configuration,it is very easy for the user to control the area of application withprecision. It is also an important fact that such an applicator may bemoved sidewise for accurately located and well defined strokes ofcosmetic material.

Where it is desirable for certain uses to provide a larger or longerapplicator element that would tend to flap in an uncontrolled manner,the invention teaches that the applicator may be reinforced by asuitable stiffener member. Preferably, the stiffener member is enclosedby the foamed plastic material. In some embodiments of the invention thefoamed plastic is in the form of an envelope with the stiifener memberextending into the interior of the envelope. In some embodiments of theinvention, the stiffener member is a rigid pin that is integral with thematerial of the applicator handel, the pin extending into an envelope offoamed plastic material.

A feature of the invention is that the stiffener member may beadvantageously of smaller longitudinal cross sectional area than theenvelope into which it extends. Thus, the foamed plastic of such anapplicator may have a freely flexible marginal end portion extendingbeyond the end of the enclosed stiffener member with two freely flexibleside marginal portions extending beyond the opposite sides of thestiffener member.

This advantage of such a stiffener inside an envelope of the open cellplastic material is that the envelope. may be relatively large withoutbeing so limber as to sacrifice close control of the area ofapplication. A special advantage is that the applicator may be movedsidewise for sidewise strokes with close control of the area of theapplied material. A further special advantage of the disclosedembodiments of the invention is that open cell foamed urethane is ofsuch light weight and delicate construction that it compares with afeather in its ability to brush the skin with exceedingly light contact.

With reference to economical fabrication of such appli cators, the opencell foamed plastic may be produced in sheets of suitable thickness topermit applicator elements to be stamped out by mass productiontechniques. In this regard, one feature of the invention is that theenvelopes may be produced by superimposing one layer of the foamedmaterial on another layer and then using a cutting die to cut throughboth layers and simultaneously applying sonic energy along the cuttingedges to seal the two cut layers together along their edges. As will beexplained, economy may also be achieved by using such a combined cuttingand sealing die to produce twin envelopes economically, the twoenvelopes being subsequently severed from each other. In one practice ofthe invention, further economy is achieved by using a handleconstruction that provides a suitable seat for the base end of thefoamed plastic envelope, the seat serving the purpose of a ferrule andthus saving the cost of a ferrule.

The various features and advantages of the invention may be understoodfrom the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, which are to beregarded as merely illustrative:

FIG. '1 is a plan view of an applicator according to one embodimentemploying an applicator element formed as an envelope with an interiorstiffener;

FIG. 2 is a side elevational view of the same;

FIG. 3 shows a narrow sheet of open cell foamed plastic material with aflat flexible plastic stiffener strip imposed on the sheet as used informing the applicator element shown in FIGS. 1 and 2;

FIG. 4 shows a second sheet placed on the first sheet to cover the fiatstiffener strip, as shown in FIG. 3;

FIG. 5 shows the outline of a double size envelope that may be stampedout of the multiple layers in FIG. 4 by means of a combined stamping andsealing die;

FIG. 6 is a perspective view showing how the applicator of FIGS. 1 and 2may be employed for a sidewise movement against a skin surface;

FIG. 7 is a plan view of an applicator according to another embodimentemploying a modified form of applicator element;

FIG. 8 is an exploded view, partly in side elevation and partly insection, showing the applicator element envelope and handle of theapplicator as shown in FIG. 7, prior to assembly;

' FIG. 9 is a plan view similar to FIG. 5 showing how a combined cuttingand sealing die may produce twin envelopes without stiffener memberstherein, as used in the applicator shown in FIG. 7;

FIG. 10 is an end view showing how the applicator of FIG. 7 may beflexed side-wise against a surface for the purpose of executing alateral stroke against the surface;

FIG. 11 is a plan view of an applicator according to still anotherembodiment;

FIG. 12 is a fragmentary side elevational View of a plastic handle withan integral flexible stiffening blade extending from the end thereof andwith the end of the handle forming a conical socket to seat the innerend'of an applicator element, as used in the applicator shown in FIG.11; and

FIG. 13 is an end elevation of the handle shown in FIG. 12.

4 DESCRIPTION OF THE SEVERAL EMBODIMENTS Referring more specifically tothe drawings, an applicator is shown in FIGS. 1 and 2 having anapplicator element mounted on a handle 56 by means of a ferrule 58, theapplicator element being in the form of an envelope of generallytriangular configuration enclosing a flat resiliently flexible stiffenermember 60.

The applicator shown in FIGS. 1 and 2 may be produced by a fabricationprocedure that includes steps illustrated in FIGS. 3, 4, and 5. FIG. .3shows a first layer 62 of the open cell foamed plastic with a thin flatflexible piece 64 of stiffening material positioned on the layertransversely thereof. It will be noted that the two opposite ends of thepiece 64 terminate short of the two opposite margins of the layer 62.

FIG. 4 shows how a second layer 65 of the open cell foamed plasticmaterial may be superimposed on the first layer 62 to cover the piece ofstiffening material 64. FIG. 5 shows the outline 66 of a double sizedenvelope that may be stamped out by a combined cutting and sealing die(not shown) with the piece of stiffener material 64 enclosed by thedouble sized envelope. Such a double sized envelope and the enclosedpiece 64 of the stiffener material may be severed along the line 68 toproduce two separate applicator elements 5-5 with stiffener members 60therein ready to be mounted on handles 56 by means of ferrules 58.

It may be noted in FIG. 1 that an end marginal portion 70 of theenvelope formed by the applicator element 55 extends beyond the end ofthe stiffener member 60 and it may be further noted that two sidemarginal portions 72 of the envelope formed by the applicator elementextends beyond the sides of the stiffener member. Each of these threemarginal portions is capable of flexure under light pressure. FIG. 6,for example, shows how the applicator shown in FIG. 1 may be applied toa skin surface with the applicator element canted for a sidewise strokeof the applicator. If the stiffener member 60 were omitted the envelopeof foamed plastic material would be excessively pliable and would simplyflop around out of control.

FIG. 7 shows an applicator element 74 mounted on a handle 75, theapplicator element being in the form of an envelope that is round inplan configuration. A stiffener member 76 inside the envelope may be inthe form of a relatively stiff tapered pin-like member 76 that is aninte gral extension of the handle 75.

A feature of this embodiment ofthe invention, as shown in FIG. 8, isthat the necessity for a ferrule is eliminated by forming a taperedsocket 78 in the end of the handle around the base of the stiffenermember 76, which socket may have a thin sharp peripheral edge 80. Theenvelope of the applicator element 7'4 has a reduced neck portion 82that seats in the socket 78 and is bonded to the surfaces of the socket.

FIG. 9 shows by means of an outline 83 how the applicator element 74 maybe produced from two layers 84 and '85 of foamed plastic, by means of asuitably combined cutting and sealing die (not shown). The outline 83defines a double sized envelope of hourglass configuration which may besevered along the line 88 to produce two applicator elements 74 withtapered neck portions.

The envelope of the applicator element 74 shown in FIG. 7 issubstantially larger than the stiffener member 76 that it enloses and isof substantially greater width than the stiffener member. Thus, theapplicator element 74 has relatively large marginal portions which maybe flexed for the application of light pressure against the users skin.FIG. 10 shows how the applicator element '74 may be canted to bring oneof the side marginal portions into light contact with the users skin.

FIG. 11 shows an applicator element'90 mounted on a handle 92, theapplicator element being in the form of an envelope with a thin fiatflexible stiffener member 94 enclosed by the envelope. As shown in FIGS.12 and 13, the flat flexible stilfener member 94 may be an integralextension of the handle 92. FIGS. 12 and 13 also show how a conicalsocket 95 may be formed in the end of the handle 92 to seat an innerportion of the envelope with the inner portion bonded to the seat.

My description in specific detail of the several embodiments of theinvention will suggest various substitutions and other departures frommy disclosure.

What is claimed is:

1. An apparatus comprising:

an elongate rigid handle having a central elongate projection at one endthereof, of less lateral dimensions than said handle, and a generallyannular shoulder at the juncture of said handle and projection, saidshoulder being flared outwardly to define, with the base of saidprojection, an axially outwardly facing annular recess;

a generally bulbous body of resiliently yieldable foamed plasticmaterial, of multiple cell thickness, having an elongate pocket thereinopen at one edge of said body, said body having a short tapering neckportion seated in said recess and secured therein; and

said elongate projection extending into said pocket and said shoulderabutting and being secured to said one edge of said body around saidpocket.

2. An applicator as defined in claim 1 wherein said projection issubstantially rigid, generally round in cross section and taperedtowards its outer end.

3. An applicator as defined in claim 1 wherein said projection is ofsubstantially flat plate-like shape whereby it is resiliently flexiblein one plane.

4. The method of making an applicator, comprising the steps of formingan elongate rigid handle with an axial projection at one end, of lesslateral dimension than said handle, and a generally annular shoulder atthe juncture of said handle and projection;

superimposing two generally flat sheets of resiliently yieldable foamedplasticmaterial or multiple cell depth;

severing said sheets and sealing the severed edges thereof together,along an outline shaped to define a body having generally bulbous endportions joined by a short central neck;

severing said neck transversely to form two generally bulbous bodieseach having a short hollow neck;

inserting said projection through said hollow neck and into body toposition the end of said neck against said shoulder; and

securing said body on said handle.

References Cited UNITED STATES PATENTS 868,609 10/1907 Martin 15244UX1,857,145 5/1932 Funk 15244(4)UX 2,946,073 7/ 1960 Vosbikian et al15244X 2,962,746 12/1960 Heroy et al. 15-244 3,105,263 lO/1963 Ginter15-244 3,228,398 1/1966 Leonard et al. 15-244X FOREIGN PATENTS 142,8178/1951 Australia -1206 1,219,860 12/1959 France 15-244 1,236,550 6/ 1960France.

DANIEL BLUM, 'Primary Examiner US. Cl. X.'R. 30021

